WO2023201225A1 - Intumescent coatings - Google Patents
Intumescent coatings Download PDFInfo
- Publication number
- WO2023201225A1 WO2023201225A1 PCT/US2023/065625 US2023065625W WO2023201225A1 WO 2023201225 A1 WO2023201225 A1 WO 2023201225A1 US 2023065625 W US2023065625 W US 2023065625W WO 2023201225 A1 WO2023201225 A1 WO 2023201225A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- intumescent coating
- combinations
- coating
- polyol
- substrate
- Prior art date
Links
- 238000000576 coating method Methods 0.000 title claims abstract description 190
- 239000011248 coating agent Substances 0.000 claims abstract description 172
- 229920005862 polyol Polymers 0.000 claims abstract description 65
- 150000003077 polyols Chemical class 0.000 claims abstract description 65
- 239000000758 substrate Substances 0.000 claims abstract description 54
- 229920002678 cellulose Polymers 0.000 claims abstract description 45
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 40
- 229920005989 resin Polymers 0.000 claims abstract description 32
- 239000011347 resin Substances 0.000 claims abstract description 32
- 239000001913 cellulose Substances 0.000 claims abstract description 27
- 239000004202 carbamide Substances 0.000 claims abstract description 25
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000004971 Cross linker Substances 0.000 claims abstract description 22
- 150000001875 compounds Chemical class 0.000 claims abstract description 22
- 238000000034 method Methods 0.000 claims abstract description 22
- 239000004114 Ammonium polyphosphate Substances 0.000 claims abstract description 20
- 235000019826 ammonium polyphosphate Nutrition 0.000 claims abstract description 20
- 229920001276 ammonium polyphosphate Polymers 0.000 claims abstract description 20
- 239000002253 acid Substances 0.000 claims abstract description 17
- 239000003054 catalyst Substances 0.000 claims abstract description 13
- 238000004132 cross linking Methods 0.000 claims abstract description 13
- 230000008569 process Effects 0.000 claims abstract description 11
- 239000012948 isocyanate Substances 0.000 claims description 25
- 150000002513 isocyanates Chemical class 0.000 claims description 25
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 claims description 24
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 claims description 24
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 24
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical group CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 claims description 24
- 239000005057 Hexamethylene diisocyanate Substances 0.000 claims description 18
- 239000002904 solvent Substances 0.000 claims description 17
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 claims description 16
- 239000002023 wood Substances 0.000 claims description 16
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 13
- 239000004568 cement Substances 0.000 claims description 13
- 239000000919 ceramic Substances 0.000 claims description 13
- 239000002131 composite material Substances 0.000 claims description 13
- 229910052751 metal Inorganic materials 0.000 claims description 13
- 239000002184 metal Substances 0.000 claims description 13
- 239000004033 plastic Substances 0.000 claims description 13
- 229920003023 plastic Polymers 0.000 claims description 13
- 229920008347 Cellulose acetate propionate Polymers 0.000 claims description 12
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 12
- XGEGHDBEHXKFPX-UHFFFAOYSA-N N-methyl urea Chemical compound CNC(N)=O XGEGHDBEHXKFPX-UHFFFAOYSA-N 0.000 claims description 12
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 12
- 239000000412 dendrimer Substances 0.000 claims description 12
- 229920000736 dendritic polymer Polymers 0.000 claims description 12
- 239000003085 diluting agent Substances 0.000 claims description 12
- 239000004254 Ammonium phosphate Substances 0.000 claims description 10
- 229910000148 ammonium phosphate Inorganic materials 0.000 claims description 10
- 235000019289 ammonium phosphates Nutrition 0.000 claims description 10
- 229920000642 polymer Polymers 0.000 claims description 10
- 239000000049 pigment Substances 0.000 claims description 9
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 8
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 8
- 239000003139 biocide Substances 0.000 claims description 8
- 239000002270 dispersing agent Substances 0.000 claims description 8
- 150000002148 esters Chemical class 0.000 claims description 8
- 150000002576 ketones Chemical class 0.000 claims description 8
- 229910000077 silane Inorganic materials 0.000 claims description 8
- 150000003672 ureas Chemical class 0.000 claims description 7
- TXBCBTDQIULDIA-UHFFFAOYSA-N 2-[[3-hydroxy-2,2-bis(hydroxymethyl)propoxy]methyl]-2-(hydroxymethyl)propane-1,3-diol Chemical compound OCC(CO)(CO)COCC(CO)(CO)CO TXBCBTDQIULDIA-UHFFFAOYSA-N 0.000 claims description 6
- PTJWCLYPVFJWMP-UHFFFAOYSA-N 2-[[3-hydroxy-2-[[3-hydroxy-2,2-bis(hydroxymethyl)propoxy]methyl]-2-(hydroxymethyl)propoxy]methyl]-2-(hydroxymethyl)propane-1,3-diol Chemical compound OCC(CO)(CO)COCC(CO)(CO)COCC(CO)(CO)CO PTJWCLYPVFJWMP-UHFFFAOYSA-N 0.000 claims description 6
- FERIUCNNQQJTOY-UHFFFAOYSA-M Butyrate Chemical compound CCCC([O-])=O FERIUCNNQQJTOY-UHFFFAOYSA-M 0.000 claims description 6
- FERIUCNNQQJTOY-UHFFFAOYSA-N Butyric acid Natural products CCCC(O)=O FERIUCNNQQJTOY-UHFFFAOYSA-N 0.000 claims description 6
- 239000005696 Diammonium phosphate Substances 0.000 claims description 6
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 6
- 239000000020 Nitrocellulose Substances 0.000 claims description 6
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 6
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 6
- FJWGYAHXMCUOOM-QHOUIDNNSA-N [(2s,3r,4s,5r,6r)-2-[(2r,3r,4s,5r,6s)-4,5-dinitrooxy-2-(nitrooxymethyl)-6-[(2r,3r,4s,5r,6s)-4,5,6-trinitrooxy-2-(nitrooxymethyl)oxan-3-yl]oxyoxan-3-yl]oxy-3,5-dinitrooxy-6-(nitrooxymethyl)oxan-4-yl] nitrate Chemical group O([C@@H]1O[C@@H]([C@H]([C@H](O[N+]([O-])=O)[C@H]1O[N+]([O-])=O)O[C@H]1[C@@H]([C@@H](O[N+]([O-])=O)[C@H](O[N+]([O-])=O)[C@@H](CO[N+]([O-])=O)O1)O[N+]([O-])=O)CO[N+](=O)[O-])[C@@H]1[C@@H](CO[N+]([O-])=O)O[C@@H](O[N+]([O-])=O)[C@H](O[N+]([O-])=O)[C@H]1O[N+]([O-])=O FJWGYAHXMCUOOM-QHOUIDNNSA-N 0.000 claims description 6
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 6
- LFVGISIMTYGQHF-UHFFFAOYSA-N ammonium dihydrogen phosphate Chemical compound [NH4+].OP(O)([O-])=O LFVGISIMTYGQHF-UHFFFAOYSA-N 0.000 claims description 6
- 229910000387 ammonium dihydrogen phosphate Inorganic materials 0.000 claims description 6
- 230000003115 biocidal effect Effects 0.000 claims description 6
- HKQOBOMRSSHSTC-UHFFFAOYSA-N cellulose acetate Chemical compound OC1C(O)C(O)C(CO)OC1OC1C(CO)OC(O)C(O)C1O.CC(=O)OCC1OC(OC(C)=O)C(OC(C)=O)C(OC(C)=O)C1OC1C(OC(C)=O)C(OC(C)=O)C(OC(C)=O)C(COC(C)=O)O1.CCC(=O)OCC1OC(OC(=O)CC)C(OC(=O)CC)C(OC(=O)CC)C1OC1C(OC(=O)CC)C(OC(=O)CC)C(OC(=O)CC)C(COC(=O)CC)O1 HKQOBOMRSSHSTC-UHFFFAOYSA-N 0.000 claims description 6
- 239000008199 coating composition Substances 0.000 claims description 6
- 239000003086 colorant Substances 0.000 claims description 6
- 239000013530 defoamer Substances 0.000 claims description 6
- 229910000388 diammonium phosphate Inorganic materials 0.000 claims description 6
- 235000019838 diammonium phosphate Nutrition 0.000 claims description 6
- 230000000855 fungicidal effect Effects 0.000 claims description 6
- 239000000417 fungicide Substances 0.000 claims description 6
- 235000019837 monoammonium phosphate Nutrition 0.000 claims description 6
- 239000006012 monoammonium phosphate Substances 0.000 claims description 6
- 229920001220 nitrocellulos Polymers 0.000 claims description 6
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 claims description 6
- 229920005906 polyester polyol Polymers 0.000 claims description 6
- 229920000570 polyether Polymers 0.000 claims description 6
- 229920000877 Melamine resin Polymers 0.000 claims description 4
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims description 4
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 claims description 3
- GZCGUPFRVQAUEE-SLPGGIOYSA-N aldehydo-D-glucose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O GZCGUPFRVQAUEE-SLPGGIOYSA-N 0.000 claims description 3
- 150000001241 acetals Chemical class 0.000 claims description 2
- 125000003172 aldehyde group Chemical group 0.000 claims description 2
- 150000001299 aldehydes Chemical class 0.000 claims description 2
- 150000002373 hemiacetals Chemical class 0.000 claims description 2
- 238000012360 testing method Methods 0.000 description 7
- -1 stain Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- RWNUSVWFHDHRCJ-UHFFFAOYSA-N 1-butoxypropan-2-ol Chemical compound CCCCOCC(C)O RWNUSVWFHDHRCJ-UHFFFAOYSA-N 0.000 description 4
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- DKGAVHZHDRPRBM-UHFFFAOYSA-N Tert-Butanol Chemical compound CC(C)(C)O DKGAVHZHDRPRBM-UHFFFAOYSA-N 0.000 description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- DKPFZGUDAPQIHT-UHFFFAOYSA-N butyl acetate Chemical compound CCCCOC(C)=O DKPFZGUDAPQIHT-UHFFFAOYSA-N 0.000 description 4
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 4
- 239000003112 inhibitor Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000003063 flame retardant Substances 0.000 description 3
- 239000012212 insulator Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- 229920002635 polyurethane Polymers 0.000 description 3
- VXQBJTKSVGFQOL-UHFFFAOYSA-N 2-(2-butoxyethoxy)ethyl acetate Chemical compound CCCCOCCOCCOC(C)=O VXQBJTKSVGFQOL-UHFFFAOYSA-N 0.000 description 2
- WMDZKDKPYCNCDZ-UHFFFAOYSA-N 2-(2-butoxypropoxy)propan-1-ol Chemical compound CCCCOC(C)COC(C)CO WMDZKDKPYCNCDZ-UHFFFAOYSA-N 0.000 description 2
- HHBZZTKMMLDNDN-UHFFFAOYSA-N 2-butan-2-yloxybutane Chemical compound CCC(C)OC(C)CC HHBZZTKMMLDNDN-UHFFFAOYSA-N 0.000 description 2
- POAOYUHQDCAZBD-UHFFFAOYSA-N 2-butoxyethanol Chemical compound CCCCOCCO POAOYUHQDCAZBD-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000006096 absorbing agent Substances 0.000 description 2
- 239000003619 algicide Substances 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 239000003759 ester based solvent Substances 0.000 description 2
- 239000012760 heat stabilizer Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000006174 pH buffer Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 2
- LLHKCFNBLRBOGN-UHFFFAOYSA-N propylene glycol methyl ether acetate Chemical compound COCC(C)OC(C)=O LLHKCFNBLRBOGN-UHFFFAOYSA-N 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- WMOVHXAZOJBABW-UHFFFAOYSA-N tert-butyl acetate Chemical compound CC(=O)OC(C)(C)C WMOVHXAZOJBABW-UHFFFAOYSA-N 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 239000002562 thickening agent Substances 0.000 description 2
- 239000004408 titanium dioxide Substances 0.000 description 2
- 239000000080 wetting agent Substances 0.000 description 2
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000004786 cone calorimetry Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000011527 polyurethane coating Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000031070 response to heat Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/18—Fireproof paints including high temperature resistant paints
- C09D5/185—Intumescent paints
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D101/00—Coating compositions based on cellulose, modified cellulose, or cellulose derivatives
- C09D101/08—Cellulose derivatives
- C09D101/10—Esters of organic acids
- C09D101/14—Mixed esters, e.g. cellulose acetate-butyrate
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D101/00—Coating compositions based on cellulose, modified cellulose, or cellulose derivatives
- C09D101/08—Cellulose derivatives
- C09D101/16—Esters of inorganic acids
- C09D101/18—Cellulose nitrate
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/02—Polyureas
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/04—Polyurethanes
Definitions
- the intumescent coating further comprises a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800.
- the intumescent coating further comprises a base coat polymer comprising at least one dendritic polyol and isocyanate.
- a base coating comprising the intumescent coating described herein.
- a substrate at least partially coated with the base coating.
- the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
- the substrate further comprises a top coat at least partially applied to the base coating, wherein the top coat comprises a silane resin.
- the silane based topcoat may be at least partially coated over the basecoat in the first stages of the fire without impairing intumescence formation and to improve chemi cal -physical resistances.
- Embodiment 17 A substrate at least partially coated with the base coating of Embodiment 16.
- Embodiment 28 An embodiment of Embodiment 26, wherein at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof.
Landscapes
- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Wood Science & Technology (AREA)
- Organic Chemistry (AREA)
- Paints Or Removers (AREA)
Abstract
The present application relates to an intumescent coating comprising: 1) at least one cellulose film forming agent; 2) at least one polyol; 3) at least one ammonium polyphosphate compound; and 4) at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker. Alternatively, an intumescent coating may comprise: 1) at least one cellulose film forming agent; 2) at least one urea-based resin; 3) at least one polyol; 4) at least one acid; and 5) at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-based resin and at least one crosslinking catalyst. Also described is a substrate with the intumescent coating described herein and a process of preparing the intumescent coating described herein.
Description
INTUMESCENT COATINGS
CROSS REFERENCE TO RELATED APPLICATION
[001] This application is an international patent application which claims the benefit of U.S. Provisional Patent Application No. 63/329,995, filed on April 12, 2022, the entire contents of which is incorporated herein by reference.
FIELD
[002] The present application relates generally to an intumescent coating. The intumescent coating may comprise: 1) at least one cellulose film forming agent; 2) at least one polyol; 3) at least one ammonium polyphosphate compound; and 4) at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker. Alternatively, the intumescent coating may comprise: 1) at least one cellulose film forming agent; 2) at least one urea-based resin; 3) at least one polyol; 4) at least one acid; and 5) at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-based resin and at least one crosslinker. A substrate with the intumescent coating described herein and a process of preparing the intumescent coatings described herein are also disclosed.
BACKGROUND
[003] Intumescent paint or intumescent coatings (collectively, “intumescent coatings”) are generally applied to the surface of a substrate to change the flaming characteristics of the surface of the substrate, so as to retard the rapid spread of fire, particularly cellulosic fires. A cellulosic fire is one characterized by a fuel source such as wood, paper, textiles, and other cellulose-based materials. In industry, intumescent coatings are applied to, for example, construction elements to increase the fire resistance limit of such elements. Intumescent coatings act to passively increase the resistance to fire. When exposed to extreme temperatures, these coatings may expand and act as an insulator.
[004] The secret behind these coatings lies in their chemical makeup. An intumescent coating may comprise a binder and other materials that soften in response to heat exposure and later
hardens into an insulating material called “char.” For the intumescent coating to be effective, the insulating layer of char needs to have enough strength to provide fire protection and protect the substrate from damage resulting from exposure to high temperatures. Such protective layer has a relatively low thermal conductivity, thereby stopping rapid thermal conduction. Intumescent coatings are used on many structures to delay the heating effects of a fire. The coating slows the rate of temperature increase of the substrate to which the coating is applied. The coating thus increases the time before the structure fails due to the heat of fire. The extra time makes it more likely that the fire may be extinguished or cooled with water before the structure fails.
[005] Currently, European legislation requires Class B rated material according to European EN 13501 to be used inside certain commercial buildings, including but not limited to retail stores, hotels, and theaters. Although a “B” rating norm may be achieved by using intumescent coating, it often comes at the cost of poor appearance as well as poor chemical resistance and other properties. Manufacturers and consumers, especially those for wood coatings, have increasingly demanded improved properties and appearances for intumescent coatings similar to a 2K solvent based polyurethane coating. In view of these challenges with many conventional intumescent coatings, the need therefore remains for improved intumescent coatings having a B rating according to European EN 13501, improved clarity and appearance, chemical resistance, and other improved properties as well as other advantages.
SUMMARY
[006] The embodiments of what is described herein are not intended to be exhaustive or to limit what is provided in the claimed subject matter and disclosed in the detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of what is provided in the claimed subject matter.
[007] An intumescent coating and processes of preparing are shown and described. The intumescent coating comprises: 1) at least one cellulose film forming agent; 2) at least one polyol; 3) at least one ammonium polyphosphate compound; and 4) at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker. Alternatively, an intumescent coating may comprise: 1) at least one cellulose film forming agent; 2) at least one urea-based resin; 3) at least
one polyol; 4) at least one acid; and 5) at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-based resin and at least one crosslinking catalyst.
[008] Also described is a substrate with the intumescent coating described herein. A process of preparing the intumescent coating is also described herein.
[009] To the accomplishment of the foregoing and related ends, the following description set forth certain illustrative aspects and implementations. These are indicative of a few of the various ways in which one or more aspects may be employed. Other aspects, advantages and novel features of the disclosure will become apparent from the following detailed description when considered.
DETAILED DESCRIPTION
[0010] Aspects of what is described herein are disclosed in the following description related to specific embodiments. Alternative embodiments may be devised without departing from the scope of what is described herein. Additionally, well-known embodiments of what is described herein may not be described in detail or will be omitted so as to not obscure the relevant details of what is described herein. Further, to facilitate an understanding of the description, discussion of several terms used herein follows.
[0011] As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” The embodiments described herein are not limiting, but rather exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the term “embodiment s)” does not require that all embodiments include the discussed feature, advantage, or mode of operation.
[0012] The present disclosure relates generally to coatings that provide advantageous improvements over current intumescent coatings. It has been discovered that the use of particular intumescent coatings, namely an intumescent coating comprising: 1) at least one cellulose film forming agent; 2) at least one polyol; 3) at least one ammonium polyphosphate compound; and 4) at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker, and, alternatively, an intumescent coating comprising: 1) at least one cellulose film forming agent; 2) at least one urea-based resin; 3) at least one polyol; 4) at least one acid; and 5) at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-
based resin and at least one crosslinking catalyst, when used in intumescent coatings having a B rating according to European EN 13501, improved clarity and appearance, chemical resistance, and other improved properties as well as other advantages.
[0013] In many embodiments, the intumescent coating is a paint, stain, varnish, clearcoat, lacquer, drying oil, or fdm. In many embodiments, the intumescent coating is a surface treatment, primer, intermediate coat, or topcoat. The intumescent coating described herein may show particular utility as clear coats, clear base coats, pigmented base coats, clear top coats, pigmented top coats, primers, and other coatings. In one embodiment, the coating is at least partially coated onto a base coat. The intumescent coating described herein is particularly suitable in the preparation of substrates, including but not limited to metal, plastics, wood, ceramics, cement, paper, fabric, composites, or combinations thereof.
Intumescent Coating with Polyurethane
[0014] In some embodiments, an intumescent coating may comprise: 1) at least one cellulose film forming agent; 2) at least one polyol; 3) at least one ammonium polyphosphate compound; and 4) at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker. The intumescent coating described herein may provide a Class B rating, according to EN 13823 Single Burning Item. Although the intumescent coating described may be prepared as a clear coating, it may also be pigmented and still provide a Class B rating.
[0015] In many embodiments, at least one cellulose film forming agent in the intumescent coating is cellulose nitrate, cellulose ester, or combinations thereof. In some embodiments, the cellulose ester is cellulose acetate propionate (CAP), cellulose ester butyrate (CAB), or combinations thereof. Although not bound by theory, at least one cellulose film may allow the intumescent coating to be thermoplastic enough to produce intumescence when exposed to fire, and the presence of nitrogen and oxygen inside the film is believed to speed up the char formation
[0016] In many embodiments, at least one cellulose film forming agent comprises from 5% to 40% by weight of the intumescent coating. In other embodiments, at least one cellulose film can, for example, range from about 5% to about 35% by weight, from about 5% to about 30% by weight, from about 10% to about 40% by weight, from about 10% to about 35% by weight, from about 10% to about 30% by weight, from about 15% to about 40% by weight, from about 15% to about 35% by weight, from about 15% to about 30% by weight, from about 15% to about 25% by
weight, from about 20% to about 40% by weight, and from about 20% to about 35% by weight. Other ranges are also contemplated.
[0017] In many embodiments, at least one polyol has at least 2 hydroxyl groups. In some embodiments, at least one polyol comprises at least one polyether polyol, at least one polyester polyol, or combinations thereof. In one embodiment, at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof.
[0018] In many embodiments, at least one polyol comprises from 2% to 40% by weight of the intumescent coating. In other embodiments, at least one polyol can, for example, range from about 2% to about 35% by weight, from about 5% to about 50% by weight, from about 5% to about 40% by weight, from about 5% to about 35% by weight, from about 5% to about 30% by weight, from about 10% to about 40% by weight, from about 10% to about 35% by weight, from about 10% to about 30% by weight, from about 15% to about 40% by weight, from about 15% to about 35% by weight, from about 15% to about 30% by weight, from about 15% to about 25% by weight, from about 20% to about 40% by weight, and from about 20% to about 35% by weight. Other ranges are also contemplated.
[0019] In many embodiments, at least one ammonium phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.
[0020] In many embodiments, at least one ammonium phosphate comprises from 10% to 50% by weight of the intumescent coating. In other embodiments, at least one ammonium phosphate can, for example, range from about 10% to about 45% by weight, from about 10% to about 40% by weight, from about 10% to about 35% by weight, from about 15% to about 50% by weight, from about 15% to about 45% by weight, from about 15% to about 40% by weight, from about 20% to about 50% by weight, from about 20% to about 45% by weight, from about 20% to about 40% by weight, from about 25% to about 50% by weight, from about 25% to about 45% by weight, from about 25% to about 40% by weight, from about 30% to about 50% by weight, and from about 30% to about 45% by weight. Other ranges are also contemplated.
[0021] In many embodiments, at least one crosslinker comprises 1) at least one compound having two or more hydroxyl groups, 2) at least one urea or modified urea resin with at least one acid, 3) at least one isocyanate, or 4) combinations thereof. In one embodiment, the at least one isocyanate is toluene diisocyanate (TDI), toluene diisocyanate (TDI) derivative, methylene diphenyl
diisocyanate (MDT), methylene diphenyl diisocyanate (MDT) derivative, hexamethylene diisocyanate (HDI), hexamethylene diisocyanate (HDI) derivative, or combinations thereof.
[0022] In many embodiments, at least one crosslinker comprises from 3% to 30% by weight of the intumescent coating when the crosslinker is measured as dry and without solvents. In other embodiments, at least one crosslinker can, for example, range from about 3% to about 25% by weight, from about 5% to about 30% by weight, from about 5% to about 25% by weight, from about 5% to about 20% by weight, from about 10% to about 30% by weight, from about 10% to about 25% by weight, from about 10% to about 20% by weight, from about 10% to about 15% by weight, from about 15% to about 30% by weight, from about 15% to about 25% by weight, from about 20% to about 30% by weight, and from about 25% to about 30% by weight. Other ranges are also contemplated.
[0023] The molar ratio is calculated based on the weight ratio amounts for the polyol and polyurethane in the intumescent coating. In many embodiments, the intumescent coating described herein has an NCO/OH ratio (isocyanate index) ranging from 0,5 to 1,2. In other embodiments, the intumescent coating has an NCO/OH ratio (isocyanate index) can, for example, range from 0,5 to 1,1, from 0,5 to 1,0, from 0,6 to 1,2, from 0,6 to 1,1, from 0,6 to 1,0, from 0,7 to 1,2, from 0,7 to 1,1, from 0,7 to 1,0, from 0,8 to 1,1, from 0,8 to 1,0, and from 0,9 to 1,1. Other ratios are also contemplated.
[0024] In some embodiments, the intumescent coating further comprises a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800. In one embodiment, the intumescent coating further comprises a base coat polymer comprising at least one dendritic polyol and isocyanate.
[0025] In many embodiments, the intumescent coating may further comprise at least one solvent comprising an alcohol, an ester, an ether, a ketone, or combinations thereof. In some embodiments, at least one solvent may comprise one or more solvents such as ketone, ester, alcohol, glycol ether, and glycol ether ester solvents. Exemplary, non-limiting examples of solvents that may be useful include propylene glycol-n-butyl ether, t-butanol, di-sec-butyl ether, n-butanol, butyl carbitol acetate, n-butyl acetate, t-butyl acetate, acetone, propylene glycol methyl ether acetate, propylene carbonate, 2-butoxyethanol, dipropylene glycol n-butyl ether, propylene glycol n-butyl ether and the like, or combinations thereof. The total amount of solvent used in the intumescent coating
described herein may be selected to provide the intumescent coating with a suitable viscosity for the application method as well as particular performance characteristics.
[0026] In many embodiments, the intumescent coating described herein is a clear coating composition. In some embodiments, the intumescent coating described herein is a pigmented coating. In one embodiment, the intumescent coating described herein may be pigmentable with pigmented pastes.
[0027] Further, the intumescent coating may comprise certain additives. In many embodiments, the intumescent coating described herein may further comprise at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof. In another embodiment, the intumescent coating may further comprise other polymers or polymer dispersions, surfactants, dispersants, defoamers, biocides, mildewcides, algaecides, thickeners, leveling agents, anti-settling agents, pH buffers, corrosion inhibitors, driers, anti-skinning agents, anti-cratering agents, anti-sag agents, heat stabilizers, UV absorbers/inhibitors, antioxidants, wetting agents, flatteners and other inert pigments (such as titanium dioxide, dyes, clay, amorphous and surface treated silica, calcium carbonate, and the like, and combinations thereof), flow agents, and the like, and various combinations thereof as needed for a particular application.
[0028] Further provided herein is a base coating comprising the intumescent coating described herein. Additionally provided is a substrate at least partially coated with the base coating. In many embodiments, the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof. In some embodiments, the substrate further comprises a top coat at least partially applied to the base coating, wherein the top coat comprises a silane resin. For this addition, the silane based topcoat may be at least partially coated over the basecoat in the first stages of the fire without impairing intumescence formation and to improve chemi cal -physical resistances.
[0029] Also provided herein is a process for producing an intumescent coating on a substrate comprising the method steps of: 1) applying the intumescent coating described herein on a substrate; and 2) curing the intumescent coating to provide a base coating on the substrate. In
many embodiments, the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
Intumescent Coating with Urea-based Resin
[0030] Also described herein is an intumescent coating comprising: 1) at least one cellulose film forming agent; 2) at least one urea-based resin; 3) at least one polyol; 4) at least one acid; and 5) at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-based resin and at least one crosslinking catalyst. In some embodiments for this intumescent coating, there are no isocyanates. In some embodiments for this intumescent coating, there are substantially no isocyanates. In other embodiments for this intumescent coating, there are limited amounts of isocyanates. The intumescent coating described herein may provide a Class B rating, according to EN 13823 Single Burning Item. Although the intumescent coating described may be prepared as a clear coating, it may also be pigmented and still provide a Class B rating.
[0031] In many embodiments, at least one cellulose fdm forming agent in the intumescent coating is cellulose nitrate, cellulose ester, or combinations thereof. In some embodiments, the cellulose ester is cellulose acetate propionate (CAP), cellulose ester butyrate (CAB), or combinations thereof. Although not bound by theory, at least one cellulose fdm may allow the intumescent coating to be thermoplastic enough to produce intumescence when exposed to fire.
[0032] In many embodiments, at least one cellulose film forming agent comprises from 5% to 40% by weight of the intumescent coating. In other embodiments, at least one cellulose film can, for example, range from about 5% to about 35% by weight, from about 5% to about 30% by weight, from about 10% to about 40% by weight, from about 10% to about 35% by weight, from about 10% to about 30% by weight, from about 15% to about 40% by weight, from about 15% to about 35% by weight, from about 15% to about 30% by weight, from about 15% to about 25% by weight, from about 20% to about 40% by weight, and from about 20% to about 35% by weight. Other ranges are also contemplated.
[0033] In some embodiments, the at least one urea-based resin is a melamine, urea resin, modified urea resin, urea-formaldehyde resin (UF resin), monomethyl urea (MMU), or combinations thereof. Other urea-based resins are also contemplated. Non-urea-based resins are also contemplated as well.
[0034] Tn many embodiments, at least one urea-based resin comprises from 5% to 25% by weight of the intumescent coating. In other embodiments, at least one urea-based resin can, for example, range from about 5% to about 20% by weight, from about 5% to about 15% by weight, from about 10% to about 25% by weight, from about 10% to about 20% by weight, from about 10% to about 15% by weight, from about 15% to about 25% by weight, and from about 15% to about 20% by weight. Other ranges are also contemplated.
[0035] In many embodiments, at least one polyol has at least 2 hydroxyl groups. In some embodiments, at least one polyol comprises at least one polyether polyol, at least one polyester polyol, or combinations thereof. In one embodiment, at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof. Tn one embodiment, at least one polyol comprises a melamine-based resin.
[0036] In many embodiments, at least one polyol comprises from 10% to 40% by weight of the intumescent coating. In other embodiments, at least one polyol can, for example, range from about 10% to about 35% by weight, from about 15% to about 40% by weight, from about 15% to about 35% by weight, from about 15% to about 30% by weight, from about 20% to about 40% by weight, from about 20% to about 35% by weight, from about 20% to about 30% by weight, from about 25% to about 40% by weight, from about 25% to about 35% by weight, from about 30% to about 40% by weight, and from about 30% to about 35% by weight. Other ranges are also contemplated.
[0037] In many embodiments, at least one acid is hydrochloric acid, phosphoric acid, sulfuric acid, phosphoric acid, sulfonic acid, or combinations thereof. In one embodiment, at least one acid is paratoluensolphonic acid. Other acids are also contemplated.
[0038] In many embodiments, at least one ammonium phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.
[0039] In many embodiments, at least one ammonium phosphate comprises from 10% to 50% by weight of the intumescent coating. In other embodiments, at least one ammonium phosphate can, for example, range from about 10% to about 45% by weight, from about 10% to about 40% by weight, from about 10% to about 35% by weight, from about 15% to about 50% by weight, from about 15% to about 45% by weight, from about 15% to about 40% by weight, from about 20% to about 50% by weight, from about 20% to about 45% by weight, from about 20% to about 40% by weight, from about 25% to about 50% by weight, from about 25% to about 45% by weight, from
about 25% to about 40% by weight, from about 30% to about 50% by weight, and from about 30% to about 45% by weight. Other ranges are also contemplated.
[0040] In many embodiments, at least one crosslinking catalyst comprises 1) at least one compound having two or more hydroxyl groups, 2) at least one urea or modified urea resin with at least one acid, 3) at least one isocyanate, or 4) combinations thereof. In one embodiment, the at least one isocyanate is toluene diisocyanate (TDI), toluene diisocyanate (TDI) derivative, methylene diphenyl diisocyanate (MD1), methylene diphenyl diisocyanate (MD1) derivative, hexamethylene diisocyanate (HDI), hexamethylene diisocyanate (HDI) derivative, or combinations thereof.
[0041] In many embodiments, at least one crosslinking catalyst comprises from 3% to 30% by weight of the intumescent coating when the crosslinking catalyst is measured as dry and without solvents. In other embodiments, at least one crosslinker can, for example, range from about 3% to about 25% by weight, from about 5% to about 30% by weight, from about 5% to about 25% by weight, from about 5% to about 20% by weight, from about 10% to about 30% by weight, from about 10% to about 25% by weight, from about 10% to about 20% by weight, from about 10% to about 15% by weight, from about 15% to about 30% by weight, from about 15% to about 25% by weight, from about 20% to about 30% by weight, and from about 25% to about 30% by weight. Other ranges are also contemplated.
[0042] The molar ratio is calculated based on the weight ratio amounts for the polyol and polyurethane in the intumescent coating. In many embodiments, the intumescent coating described herein has an NCO/OH ratio (isocyanate index) ranging from 0,5 to 1,2. In other embodiments, the intumescent coating has an NCO/OH ratio (isocyanate index) can, for example, range from 0,5 to 1,1, from 0,5 to 1,0, from 0,6 to 1,2, from 0,6 to 1,1, from 0,6 to 1,0, from 0,7 to 1,2, from 0,7 to 1,1, from 0,7 to 1,0, from 0,8 to 1,1, from 0,8 to 1,0, and from 0,9 to 1,1. Other ratios are also contemplated.
[0043] In some embodiments, the intumescent coating further comprises a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800. In one embodiment, the intumescent coating further comprises a base coat polymer comprising at least one dendritic polyol and isocyanate.
[0044] Tn many embodiments, the intumescent coating may further comprise at least one solvent comprising an alcohol, an ester, an ether, a ketone, or combinations thereof. In some embodiments, at least one solvent may comprise one or more solvents such as ketone, ester, alcohol, glycol ether, and glycol ether ester solvents. Exemplary, non-limiting examples of solvents that may be useful include propylene glycol-n-butyl ether, t-butanol, di-sec-butyl ether, n-butanol, butyl carbitol acetate, n-butyl acetate, t-butyl acetate, acetone, propylene glycol methyl ether acetate, propylene carbonate, 2-butoxyethanol, dipropylene glycol n-butyl ether, propylene glycol n-butyl ether and the like, or combinations thereof. The total amount of solvent used in the intumescent coating described herein may be selected to provide the intumescent coating with a suitable viscosity for the application method as well as particular performance characteristics.
[0045] In many embodiments, the intumescent coating described herein is a clear coating composition. In some embodiments, the intumescent coating described herein is a pigmented coating. In one embodiment, the intumescent coating described herein may be pigmentable with pigmented pastes.
[0046] Further, the intumescent coating may comprise certain additives. In many embodiments, the intumescent coating described herein may further comprise at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof. Tn another embodiment, the intumescent coating may further comprise other polymers or polymer dispersions, surfactants, dispersants, defoamers, biocides, mildewcides, algaecides, thickeners, leveling agents, anti-settling agents, pH buffers, corrosion inhibitors, driers, anti-skinning agents, anti-cratering agents, anti-sag agents, heat stabilizers, UV absorbers/inhibitors, antioxidants, wetting agents, flatteners and other inert pigments (such as titanium dioxide, dyes, clay, amorphous and surface treated silica, calcium carbonate, and the like, and combinations thereof), flow agents, and the like, and various combinations thereof as needed for a particular application.
[0047] Further provided herein is a base coating comprising the intumescent coating described herein. Additionally provided is a substrate at least partially coated with the base coating. In many embodiments, the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof. In some embodiments, the substrate further comprises a top coat at least
partially applied to the base coating, wherein the top coat comprises a silane resin. For this addition, the silane based topcoat may be at least partially coated over the basecoat in the first stages of the fire without impairing intumescence formation and to improve chemi cal -physical resistances.
[0048] Also provided herein is a process for producing an intumescent coating on a substrate comprising the method steps of: 1) applying the intumescent coating described herein on a substrate; and 2) curing the intumescent coating to provide a base coating on the substrate. In many embodiments, the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
Experimental Results
[0049] The classification parameter FIGRA, Fire Growth Rate, provides a way to classify the fire properties of building products for the purpose of the Construction Products Derivative (CPD) and is the main parameter for classification of building products based on the SBI (Single Burning Item) test. It predicts burning behavior of a large variety of building products in reference scenarios based on real life fire scenarios. FIGRA is defined as the growth rate of the burning intensity, HRR, during a test (e.g. SBI). FIGRA is calculated as the maximum value of the function (heat release rate)/ (elapsed test time) and provided as W/s.
[0050] Tn addition, certain threshold values of HRR and the total heat release rate must first be reached before FIGRA is calculated. Threshold values are needed to avoid that very small and early values of HRR are included as this leads to unrealistic FIGRA values. The detailed definition of FIGRA can be found in EN 13823 Single Burning Item (SBI). SBI evaluates the potential contribution of a surface lining to the development of a fire. It simulates a single burning item in a corner of a room. The test is used for the European classes Al, A2, B, C and D. For the fire classification system, the following ratings and test methods are provided below in Table 1.
Table 1: Fire Ratings
[0051] Based on EN 13823, the following testing was performed below in Table 2. Results were prepared both in with vacuum and high pressure equipment by Cone Calorimetry method according to EN 13823-2020 for FIGRA and by actual FIGRA testing by Single Burning Item (SBI) method according to EN 13823-2020. TSP, or Total Smoke Reduction, was also measured.
Table 2
[0052] From Table 2, Class B may be achieved on pine substrate using the intumescent coating described herein. Further, Class B may be achieved on MDF substrate using the intumescent coating described herein along with an insulator coat or sealing coat. However, the intumescent coating is absorbed into the wood in the first two results (with a FIGRA average of 144), resulting in a Class C rating.
[0053] Further, additional testing provided the following data in Table 3 based on EN 13823.
Table 3
[0054] From the results in Table 3, Class B may be achieved on MDF substrate (20 mm) for Example 1. Due to the absorption characteristic of the MDF, pigments or an insulator coat (as shown in Table 2) may provide improved ratings for the fire class. The addition of a fire retardant (FR) to the intumescent coating (from Example 1) in Example 2 did not provide a Class B rating. Further, adding certain amounts of pigmented pastes, even with the addition of a fire retardant additive in Example 4, did not provide a Class B rating.
[0055] For Table 4, nearly all Examples achieved a Class B rating on MDF (20 mm) except the white pigmented sample (Example 2). Example 2 did not achieve a Class B rating only due to the THR600 rating of 7.5. For Class B, it must be less than or equal to 7,5. It is speculated that adjustments to the amount of white pigmented paste may allow a white pigmented system to achieve a Class B rating.
Embodiments
[0056] The following embodiments are contemplated. All combinations of features and embodiments are contemplated.
[0057] Embodiment 1: An intumescent coating comprising: 1) at least one cellulose fdm forming agent; 2) at least one polyol; 3) at least one ammonium polyphosphate compound; and 4) at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker.
[0058] Embodiment 2: An embodiment of Embodiment 1, wherein at least one cellulose film forming agent is cellulose nitrate, cellulose ester, or combinations thereof.
[0059] Embodiment 3: An embodiment of Embodiment 2, wherein the cellulose ester is cellulose acetate propionate (CAP), cellulose ester butyrate (CAB), or combinations thereof.
[0060] Embodiment 4: An embodiment of any of Embodiments 1 -3, wherein at least one polyol has at least 2 hydroxyl groups.
[0061] Embodiment 5: An embodiment of Embodiment 4, wherein at least one polyol comprises at least one polyether polyol, at least one polyester polyol, or combinations thereof.
[0062] Embodiment 6: An embodiment of Embodiment 4, wherein at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof.
[0063] Embodiment 7: An embodiment of any of Embodiments 1-6, wherein at least one ammonium phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.
[0064] Embodiment 8: An embodiment of any of Embodiments 1-7, wherein at least one crosslinker comprises 1) at least one compound having two or more hydroxyl groups, 2) at least one urea or modified urea resin with at least one acid, 3) at least one isocyanate, or 4) combinations thereof.
[0065] Embodiment 9: An embodiment of Embodiment 8, wherein the at least one isocyanate is toluene diisocyanate (TDI), toluene diisocyanate (TDI) derivative, methylene diphenyl diisocyanate (MDI), methylene diphenyl diisocyanate (MDI) derivative, hexamethylene diisocyanate (HDI), hexamethylene diisocyanate (HDI) derivative, or combinations thereof.
[0066] Embodiment 10: An embodiment of any of Embodiments 1-9, wherein a molar ratio of OH/NCO is 0,5 to 1,2.
[0067] Embodiment 11: An embodiment of any of Embodiments 1-10 further comprising a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800.
[0068] Embodiment 12: An embodiment of any of Embodiments 1-11, further comprising a base coat polymer comprising at least one dendritic polyol and isocyanate.
[0069] Embodiment 13: An embodiment of any of Embodiments 1 -12 further comprising at least one solvent comprising an alcohol, an ester, an ether, a ketone, or combinations thereof.
[0070] Embodiment 14: An embodiment of any of Embodiments 1-13, wherein the intumescent coating is a clear coating composition.
[0071] Embodiment 15: An embodiment of any of Embodiments 1 -14 further comprising at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof.
[0072] Embodiment 16: A base coating comprising the intumescent coating of any of Embodiments 1-15.
[0073] Embodiment 17: A substrate at least partially coated with the base coating of Embodiment 16.
[0074] Embodiment 18: An embodiment of Embodiment 17, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
[0075] Embodiment 19: An embodiment of any of Embodiments 17-18 further comprising a top coat at least partially applied to the base coating, wherein the top coat comprises a silane resin.
[0076] Embodiment 20: A process for producing an intumescent coating on a substrate comprising the method steps of: 1) applying the intumescent coating of any of Embodiments 1 to 15 on a substrate; and 2) curing the intumescent coating to provide a base coating on the substrate.
[0077] Embodiment 21 : An embodiment of Embodiment 20, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
[0078] Embodiment 22: An intumescent coating comprising: 1) at least one cellulose fdm forming agent; 2) at least one urea-based resin; 3) at least one polyol; 4) at least one acid; and 5) at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-based resin and at least one crosslinking catalyst.
[0079] Embodiment 23: An embodiment of Embodiment 22, wherein at least one cellulose film forming agent is cellulose nitrate, cellulose ester, or combinations thereof.
[0080] Embodiment 24: An embodiment of Embodiment 23, wherein the cellulose ester is cellulose acetate propionate (CAP), cellulose ester butyrate (CAB), or combinations thereof.
[0081] Embodiment 25: An embodiment of any of Embodiments 22-24, wherein the at least one urea-based resin is a melamine, urea resin, modified urea resin, urea-formaldehyde resin (UF resin), monomethyl urea (MMU), or combinations thereof.
[0082] Embodiment 26: An embodiment of any of Embodiments 22-25, wherein at least one polyol has at least 2 hydroxyl groups.
[0083] Embodiment 27 : An embodiment of Embodiment 26, wherein at least one polyol comprises at least one polyether polyol, at least one polyester polyol, or combinations thereof.
[0084] Embodiment 28: An embodiment of Embodiment 26, wherein at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof.
[0085] Embodiment 29: An embodiment of any of Embodiments 22-28, wherein at least one acid is hydrochloric acid, phosphoric acid, sulfuric acid, phosphoric acid, sulfonic acid, or combinations thereof.
[0086] Embodiment 30: An embodiment of any of Embodiments 22-29, wherein at least one ammonium phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.
[0087] Embodiment 31 : An embodiment of any of Embodiments 22-30 further comprising at least one crosslinking catalyst, wherein the at least one crosslinking catalyst comprises 1) at least one compound having two or more aldehyde groups, acetals or hemiacetals of the aldehydes, 2) at least one compound having two or more hydroxyl groups, 3) at least one isocyanate, or 4) combinations thereof.
[0088] Embodiment 32: An embodiment of Embodiment 31, wherein the at least one isocyanate is toluene diisocyanate (TDI), toluene diisocyanate (TDI) derivative, methylene diphenyl diisocyanate (MDI), methylene diphenyl diisocyanate (MDI) derivative, hexamethylene diisocyanate (HDI), hexamethylene diisocyanate (HDI) derivative, or combinations thereof.
[0089] Embodiment 33: An embodiment of any of Embodiments 22-32, wherein a molar ratio of OH/NCO is 0,5 to 1,2.
[0090] Embodiment 34: An embodiment of any of Embodiments 22-33 further comprising a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800.
[0091] Embodiment 35: An embodiment of any of Embodiments 22-34 further comprising a base coat polymer comprising at least one dendritic polyol and isocyanate.
[0092] Embodiment 36: An embodiment of any of Embodiments 22-35 further comprising at least one solvent comprising an alcohol, an ester, an ether, a ketone, or combinations thereof.
[0093] Embodiment 37: An embodiment of any of Embodiments 22-36, wherein the intumescent coating is a clear coating composition.
[0094] Embodiment 38: An embodiment of any of Embodiments 22-37 further comprising at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof.
[0095] Embodiment 39: A base coating comprising the intumescent coating of any of Embodiments 22-38.
[0096] Embodiment 40: A substrate at least partially coated with the base coating of Embodiment 39.
[0097] Embodiment 41: An embodiment of Embodiment 40, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
[0098] Embodiment 42: An embodiment of any of Embodiments 40-41 further comprising a top coat at least partially applied to the base coating, wherein the top coat comprises a silane resin.
[0099] Embodiment 43: A process for producing an intumescent coating on a substrate comprising the method steps of: 1) applying the intumescent coating of any of Embodiments 22 to 38 on a substrate; and 2) curing the intumescent coating to provide a base coating on the substrate.
[00100] Embodiment 44: An embodiment of Embodiment 43, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
[00101] What has been described above includes examples of the claimed subject matter. All details and any described modifications in connection with the Background and Detailed Description are within the spirit and scope of the claimed subject matter will be readily apparent to those of skill in the art. In addition, it should be understood that aspects of the claimed subject
matter and portions of various embodiments and various features recited below and/or in the appended claims may be combined or interchanged either in whole or in part. In the foregoing descriptions of the various embodiments, those embodiments which refer to another embodiment may be appropriately combined with other embodiments as will be appreciated by one of skill in the art. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the claimed subject matter, realizing that many further combinations and permutations of the claimed subject matter are possible. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
Claims
What is claimed is:
1. An intumescent coating comprising: at least one cellulose film forming agent; at least one polyol; at least one ammonium polyphosphate compound; and at least one crosslinker; wherein at least one polyol is reacted with at least one crosslinker.
2. The intumescent coating of Claim 1, wherein at least one cellulose film forming agent is cellulose nitrate, cellulose ester, or combinations thereof.
3. The intumescent coating of Claim 2, wherein the cellulose ester is cellulose acetate propionate (CAP), cellulose ester butyrate (CAB), or combinations thereof.
4. The intumescent coating of any of Claims 1-3, wherein at least one polyol has at least 2 hydroxyl groups.
5. The intumescent coating of Claim 4, wherein at least one polyol comprises at least one polyether polyol, at least one polyester polyol, or combinations thereof.
6. The intumescent coating of Claim 4, wherein at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof.
7. The intumescent coating of any of Claims 1-6, wherein at least one ammonium phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.
8. The intumescent coating of any of Claims 1-7, wherein at least one crosslinker comprises 1) at least one compound having two or more hydroxyl groups, 2) at least one urea or modified urea resin with at least one acid, 3) at least one isocyanate, or 4) combinations thereof.
The intumescent coating of Claim 8, wherein the at least one isocyanate is toluene diisocyanate (TDI), toluene diisocyanate (TDI) derivative, methylene diphenyl diisocyanate (MDI), methylene diphenyl diisocyanate (MDI) derivative, hexamethylene diisocyanate (HDI), hexamethylene diisocyanate (HDI) derivative, or combinations thereof. The intumescent coating of any of Claims 1-9, wherein a molar ratio of OH/NCO is 0,5 to 1,2. The intumescent coating of any of Claims 1-10 further comprising a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800. The intumescent coating of any of Claims 1-11 further comprising a base coat polymer comprising at least one dendritic polyol and isocyanate. The intumescent coating of any of Claims 1-12 further comprising at least one solvent comprising an alcohol, an ester, an ether, a ketone, or combinations thereof. The intumescent coating of any of Claims 1-13, wherein the intumescent coating is a clear coating composition. The intumescent coating of any of Claims 1-14 further comprising at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof. A base coating comprising the intumescent coating of any of Claims 1-15. A substrate at least partially coated with the base coating of Claim 16.
18. The substrate of Claim 17, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
19. The substrate of any of claims 17-18, further comprising a top coat at least partially applied to the base coating, wherein the top coat comprises a silane resin.
20. A process for producing an intumescent coating on a substrate comprising the method steps of: applying the intumescent coating of any of Claims 1 to 15 on a substrate; and curing the intumescent coating to provide a base coating on the substrate.
21. The substrate of Claim 20, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
22. An intumescent coating comprising: at least one cellulose film forming agent; at least one urea-based resin; at least one polyol; at least one acid; and at least one ammonium polyphosphate compound; wherein at least one polyol is reacted with at least one urea-based resin and at least one crosslinking catalyst.
23. The intumescent coating of Claim 22, wherein at least one cellulose film forming agent is cellulose nitrate, cellulose ester, or combinations thereof.
24. The intumescent coating of Claim 23, wherein the cellulose ester is cellulose acetate propionate (CAP), cellulose ester butyrate (CAB), or combinations thereof.
25. The intumescent coating of any of Claims 22-24, wherein the at least one urea-based resin is a melamine, urea resin, modified urea resin, urea-formaldehyde resin (UF resin), monomethyl urea (MMU), or combinations thereof
26. The intumescent coating of any of Claims 22-25, wherein at least one polyol has at least 2 hydroxyl groups.
27. The intumescent coating of Claim 26, wherein at least one polyol comprises at least one polyether polyol, at least one polyester polyol, or combinations thereof.
28. The intumescent coating of Claim 26, wherein at least one polyol comprises pentaerythritol, dipentaerythritol, tripentaerythritol, or combinations thereof.
29. The intumescent coating of any of Claims 22-28, wherein at least one acid is hydrochloric acid, phosphoric acid, sulfuric acid, phosphoric acid, sulfonic acid, or combinations thereof.
30. The intumescent coating of any of Claims 22-29, wherein at least one ammonium phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.
31. The intumescent coating of any of Claims 22-30, further comprising at least one crosslinking catalyst, wherein the at least one crosslinking catalyst comprises 1) at least one compound having two or more aldehyde groups, acetals or hemiacetals of the aldehydes, 2) at least one compound having two or more hydroxyl groups, 3) at least one isocyanate, or 4) combinations thereof.
32. The intumescent coating of Claim 31, wherein the at least one isocyanate is toluene diisocyanate (TDI), toluene diisocyanate (TDI) derivative, methylene diphenyl diisocyanate (MDI), methylene diphenyl diisocyanate (MDI) derivative, hexamethylene diisocyanate (HDI), hexamethylene diisocyanate (HDI) derivative, or combinations thereof.
33. The intumescent coating of any of Claims 22-32, wherein a molar ratio of OH/NCO is 0,5 to 1,2.
34. The intumescent coating of any of Claims 22-33 further comprising a dendritic polymer having hydroxyl groups, wherein the dendritic polymer has a hydroxyl number in the range of 80 to 800.
35. The intumescent coating of any of Claims 22-34 further comprising a base coat polymer comprising at least one dendritic polyol and isocyanate.
36. The intumescent coating of any of Claims 22-35, further comprising at least one solvent comprising an alcohol, an ester, an ether, a ketone, or combinations thereof.
37. The intumescent coating of any of Claims 22-36, wherein the intumescent coating is a clear coating composition.
38. The intumescent coating of any of Claims 22-37 further comprising at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof.
39. A base coating comprising the intumescent coating of any of Claims 22-38.
40. A substrate at least partially coated with the base coating of Claim 39.
41. The substrate of Claim 40, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
42. The substrate of any of Claims 40-41, further comprising a top coat at least partially applied to the base coating, wherein the top coat comprises a silane resin.
43. A process for producing an intumescent coating on a substrate comprising the method steps of: applying the intumescent coating of any of claims 22 to 38 on a substrate; and curing the intumescent coating to provide a base coating on the substrate.
44. The process of Claim 43, wherein the substrate comprises metal, plastics, wood, ceramics, cement, composites, or combinations thereof.
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US202263329995P | 2022-04-12 | 2022-04-12 | |
US63/329,995 | 2022-04-12 |
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